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Utica Boilers SFH-W IV Operation and Installation Manual

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1. A g L poi iro In Fn PRESSURE REDUCING VALVE FEED L WATER LE L B n EOM varve lI ET gt RETURN 10 CONNECTING SUPPLY AND RETURN PIPING Figure 7 Mixing Valve Piping GUBEU SYSTEM f TEMPERATURE 4 WAY MIXING VALVE EXPANSION TANK Figure Z8 Primary Secondary Piping With Bypass RETURN SYSTEM SYSTEM TEMPERATURE CIR GAUGE aoe cu FLOW i VALVE MAX SUPPLY yy AA QE GATE VALVE REDUCED PRESSURE BACKFLOW PREVENTER A PRESSURE REDUCING VALVE 11 CONNECTING SUPPLY AND RETURN PIPING 8 Typical indirect water heater installation using circulators is shown in Figure 9 9 Typical indirect water heater installation using zone valves is shown in Figure 10 Figure 9 Indirect Water Heater Piping with Circulator GATE VALVE FLOW CONTROL REDUCED PRESSURE OR CHECK VALVE BACKFLOW PREVENTER E SYSTEM H CIR s TANK TT CIR gt Ar o r E D I ao HOT WATER yo AER COLD WATER INLET OUTLET PRESSURE a me REDUCING v mm FEED AT WATER 1 H SYSTEM d RETURN x m THERMAL NL TRAP RELIEF VALVE WIRING FOR DRAIN VALVE t THERMOSTAT lt PUMP CONTROL Figure 10 Indirect Water Heater Piping with Zone Valve SYSTEM ZONE GATE VALVE VALVE REDUCED PRESSURE BACKFLOW PREVENTER SYSTEM RETURN TANK ZONE E VALVE E A r y AAH EE M Tt n o T V A x m te
2. 10 Install discharge piping from safety relief valve Figure 11 Discharge Piping From Safety e Use 3 4 or larger pipe See Figure 11 Relief Valve e Individual boiler discharge piping shall be SAFETY RELIEF VALVE independent of other discharge piping e Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity M DISCHARGE below minimum relief valve capacity stated on T PIPING rating plate Pte e Install union if used close to safety relief valve I p outlet F e Install elbow s if used close to safety relief valve outlet and downstream of union if used BOILER Check local codes for maximum distance from floor or allowable safe point of discharge 1 13 CONNECTING SUPPLY AND RETURN PIPING Figure 12 Recommended Piping For Boilers Equipped With T3 Or T4 Tankless Heater ADJUSTABLE PRESSURE GAUGE OPTIONAL FLOW RESTRICTOR R WATTS N P3 OR EQUIV WATER SUPPLY CONTROL c 0 TEMPERED DOMESTIC WATER 100 130 DEGREE TEMPERING VALVE oo LOCATED 8 12 BELOW OUTLET OF COIL y DANGER Water temperatures exceeding 125 F will cause severe burns instantly or death by scalding e Automatic mixing valve must be installed on outlet of domestic coil Installation must comply with valve manufacturer s recommendations and instructions Do not remove bolts or limit at time of installation Pipe in accordance with boiler s Installa
3. 3 of the Energy Policy and Conservation Act this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the Same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decreases This boiler is not used for any space heating This boiler is part of a modular or multiple boiler system having a total input of 300 000 BTU hr or greater This boiler is equipped with a tankless coil UTICA BOILERS UTICA 2201 Dwyer Avenue BOILERS S 3B 3 S wwOC 9 w Y9 9 V VV OU p C Utica NY 13501 web site www ecrinternational com
4. systems only vent pump as soon as burner starts Allow oil to run until all traces of air in the suction line disappear H Turn OFF burner and install pressure gauge port on pump I Start burner again and check oil pressure per setup charts on page 24 Adjust if necessary Do not set fire visually Instruments are only reliable method to determine proper air adjustments Improperly adjusted burner causes soot and high fuel bills because of incomplete combustion of fuel oil This in turn may require excessive boiler maintenance service costs and in some instances house cleaning or redecorating A competent service mechanic should be consulted to make proper adjustments with smoke tester CO indicator and draft gauge Instructions For Proper Operation Of Boiler Burner Unit A 1 4 diameter slot is provided in inspection cover plate to take draft readings in combustion chamber See Figure 26 A 1 4 diameter hole will be required in flue pipe between boiler and barometric damper if used to take draft CO smoke and temperature readings Adjust air shutter on oil burner to obtain trace of smoke Measure CO at this point Increase air adjustment to lower CO approximately one 1 percent Check to insure minimum negative 02 w c water column overfire draft and zero 0 smoke If 02 w c overfire draft can not be maintained changes and or modifications may be required in venting or chimney Fo
5. 3 C If horizontal ducts are used each opening shall have a minimum free area 1 square inch per 2 000 Btu per hour total input rating of all appliances in the enclosed space See Figure 4 D When ducts are used they shall be of the same cross sectional area as the free area of the area of the openings to which they connect The minimum dimension of rectangular air ducts shall not be less than 3 inches In calculating free area using louvers grills or screens for the above consideration shall be given to their blocking effect Screens used shall not be smaller than 1 4 inch mesh If the free area through a design of louver or grill is known it should be used in calculating the size opening required to provide the free area specified If the design and free area is not known it may be assumed that wood louvers will have 20 25 free area and metal louvers and grills will have 60 75 free area Louvers and grills shall be fixed in the open position or interlocked with the boiler so that they are opened automatically during boiler operation Refer to the Combustion Air Requirements chart on previous page for combustion air minimum opening requirements VENTILATION amp COMBUSTION AIR Figure 2 CHIMNEY VENTILATION LOUVERS L TYPE VENT A EACH END OF ATTIC VENTILATION LOUVERS i UNHEATED CRAWL SPACE Figure 3 Figure 4 CHIMNEY CHIMNEY VENTILATION LOUVERS OR L TYPE VENT N EACH END OF ATTIC L TYPE VEN
6. CARLIN 60200 crN PRIMARY CONTROL PNK OPERATING INSTRUCTIONS Operating Instructions 1 Inspect venting system at start of each heating season 2 Check vent pipe from boiler to chimney for signs of deterioration by rust or sagging joints Repair if necessary 3 Remove vent pipe at base of chimney or flue and using mirror check for obstruction Safety Relief Valve Burn and scald hazard Safety relief valve could discharge steam or hot water during operation e Operate lever of safety relief valve on boiler periodically to make sure it is functioning properly e Safety relief valve should open before water pressure exceeds 30 psi reading on gauge e If this pressure is exceeded and safety relief valve Starts leaking water when boiler is operating at normal pressures it should be immediately replaced e Corrosion can build up rapidly at valve seat and prevent its functioning as safety device See Figure 11 page 13 Start Up And Adjustment Of Oil Burner See oil burner instructions for nozzle and electrode setting A Check oil burner nozzle to verify it is tight in the adapter B Check electrode setting may have been jarred out of position during transportation C Burner mounting bolts should be tight D Set room thermostat to call for heat or jump thermostat contacts on the boiler control Open all oil line valves Turn service switch on Burner should start G On one pipe fuel
7. High Limit and Circulator Control Primary Control For Tankless Heater Units add Tankless Hot Water Coil and Triple Combination High Limit Low Limit Circulator Control TANKLESS WATER HEATER CAPACITIES BOILER INPUT TANKLESS REAR DRS BOILER MODEL RATE HEATER INTERMITTENT DRAW WATER CONTENT NUMBER G P H NUMBER G P M GALS SFH 3085WT SFH 3100WT SFH 4100WT INTRODUCTION Improper installation adjustment alteration service or maintenance could result in death or serious injury Installation must conform to requirements of the authority having jurisdiction Such applicable requirements take precedence over the general instructions of this manual Install boiler in accordance with requirements of authority having jurisdiction or in the absence of such requirements CSA B139 Installation Code for Oil Burning Equipment Where required by the authority having jurisdiction the installation must conform to the American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME No CSD 1 LOCATE BOILERS in front of final position before removing crate Provide level solid base as near the chimney as possible and centrally located with respect to heat distribution system as practical e Allow 24 inches in the front and top for servicing and cleaning or removing tankless water heating coil e When installed in utility room door should be wide enough to allow
8. NOZZLE NOZZLE MODEL MODEL RATE MER TYPE SETTING 3085 EZ 1HP DELAVAN 0 75 x 70 B BLANK 3100 EZ 1HP DELAVAN 0 85 x 70 B 0 85 1 00 BLANK 4100 EZ 1HP DELAVAN 0 85 x 70 B 0 85 1 00 BLANK 4125 EZ iHP DELAVAN 1 00 x 70 B 0 85 1 00 BLANK 4145 EZ iHP DELAVAN 1 20 x 70 B 1 10 1 25 BLANK 5160 EZ 2HP DELAVAN 1 35 x 70 B 0 85 1 00 3 SLOT 5185 EZ 2HP DELAVAN 1 50 x 70 B 3 SLOT 6175 EZ 2HP DELAVAN 1 50 x 60 B 3 SLOT 6210 EZ 2HP DANFOSS 1 75 x 70 AS 1 65 1 95 OPEN Above settings are preliminary settings only Final adjustments must be made using combustion test instruments as previously outlined in the Operating Instructions 25 Figure 26 OPERATING INSTRUCTIONS SAFETY RELIEF VALVE TOP JACKET PANEL HIGH LIMIT CONTROL 1 4 SLOT BURNER ELECTRICAL LOWER FRONT JACKET PANEL MOUNTING SCREWS BOTH SIDES Instructions For Closing Burner Swing Door 1 Swing burner and door to right until insulation is slightly compressed and stud is exposed 2 Attach nut to stud and tighten until built in stop contacts the mounting door Replace oil line to burner Replace lower jacket panel and tighten screws 5 Connect power cable at factory supplied burner electrical disconnect Turn on power to boiler 7 Bleed oil line 26 SERVICE RECORD i euoud X sseJppy Aueduio5 s eirjiu u 59j R euieN Aueduio5 peulrioJJag 923IAJoS IMPORTANT In accordance with Section 325 f
9. RING Figure 20 Wiring Diagram Riello 40F5 without Tankless Heater LIMIT SENSOR THERMOSTAT 24 VOLT BY INSTALLER I BURNER CUNTROL RIELLU 530SEC PRIMARY CONTROL PNK GRN BLK WHT 120V 60 HZ SUPPLY BY INSTALLER CIRCULATOR Figure 21 Wiring Diagram Riello 40F5 with Tankless Heater 120V 60 HZ SUPPLY BY INSTALLER THERMOSTAT 24 VOLT BY INSTALLER BURNER CONTROL IKIELLTI S3SUSEL PRIMARY CUNTROL PNK GRN SHUTTER WHT B ASSY BLK L8124 CIRCULATOR 20 ELECTRICAL WIRING Figure 22 Wiring Diagram Riello 40F10 without Tankless Heater LIMIT SENSOR THERMOSTAT 24 VOLT BY INSTALLER 315 BURNER CUNTRUL RIECCEH DS0SE7U PRIMARY CLINTRLIL 120V 60 HZ SUPPLY BY INSTALLER CIRCULATOR Figure 23 Wiring Diagram Riello 40F10 with Tankless Heater 120V 60 HZ SUPPLY BY INSTALLER E THERMOSTAT 24 VOLT BY INSTALLER BURNER CONTROL RIELLU S3USEJZE PRIMARY CUNTRUL GRN WHT BLK L8124 CIRCULATOR 21 ELECTRICAL WIRING Figure 24 Wiring Diagram Carlin EZ 1 2 without Tankless Heater THERMOSTAT 24 VOLT BY INSTALLER BY CIRCULATOR Figure 25 Wiring Diagram Carlin EZ 1 2 with Tankless Heater 120V 60 HZ SUPPLY BY INSTALLER THERMOSTAT 24 VOLT BY INSTALLER L8124 CIRCULATOR 22 GRN PRIMARY CONTROL PNK GRN ZA Yee WHT BLK BURNER CONTROL CARLIN 60200 BURNER CONTROL
10. STARFIRE IV SERIES 4 UNG WATER ae OIL FIRED CAST IRON BOILER Models r INSTALLATION OPERATION amp SFH 4100 MAINTENANCE MANUAL SFH 4125 SFH 4145 SFH 5160 SFH 5185 SFH 6175 SFH 6210 ecr Shortens Sa NS An ISO 9001 2008 Certified Company P N 240009735 Rev F 12 2014 TABLE OF CONTENTS DIMENSIONS weserskcs vus wERPEE E REX ERN EVE VY ACHNIDR UU UN EIER UR EN EA UNE KR EE VHVE EHE EWR NT USE LPEFENR nasa aa 3 Boiler Ratings amp Capaciti S axz2aaaannvnnnnunnnnannnunnnnnnnnunnnnnnnnunnunnnnnnnnnnnnnnnnnnnnnnnnunnnnnnnnnnnnnnnnua M odUCO eE EER A M M 5 Ventilation amp Combustion Air aaanaanannnnnnnnunnnunnununnnnunnunnnnnnnnnnnnnnununnnnunnnnunnnnunnnnnnnnnnnnnnnnnnnna 6 Connecting Supply And Return PIPING 2anananaannnnnnnnsnnununnnnunnununnnnnnnnnnnnnnnnnnnnunnunnnnnnnnnnnunnnnnn 9 System PIDING vcteciwsciarssnatancsvanradsusstanwsveoracserisiawonserseuetedvivaasnsesertqusceninissndslaueyrcrarscusianes 13 Venting System Inspection amp InstallatiOn aaaaaaaaasnsnnnu nnnnunnnnnnnnnnnnnnunnnnunnnnnnnnnunnununnnu 16 Oil Tank And Piping 2annnnnnannnn nnnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnununnununnnnnnnnnunnnnnnnnnnnnnnunnnnnnnnnnnnnnnnnnnn UE 17 Electricat WIFIBIG sens HORDEO EROR REA OCA ORE c RC C ICD CO ROC ENAS RA RRR an a Aa a 18 Operating Instructions azaanannnnnnnnnnnunnunnnnnnnnnnnnnnnnnnnnnnnnnnnununnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 23 Keep this manual near boiler and R
11. T Z iss OUTLET AIR DUCT E 4 INLET AIR DUCT CONNECTING SUPPLY AND RETURN PIPING 1 Connect supply and return piping as suggested in Figure 5 below When boiler is used in connection with refrigerated systems A Chilled medium MUST BE IN PARALLEL with boiler B Use appropriate valves to prevent chilled medium from entering heating boiler 2 During heating cycle open valves A and B close valves C and D 3 During heating cooling cycle open valves C and D close valves A and B A Maintain minimum clearance of one inch to hot water pipes In air handling units where they may be exposed to refrigerated air circulation boiler piping system MUST be supplied with flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle Figure 5 Typical Piping Configuration REDUCED PRESSURE BACKFLOW PREVENTER A H 4 Hot water boilers installed above radiation level must be provided with low water device either as part of boiler or at time of boiler installation When boiler is connected to heating system utilizing multiple zoned circulators each circulator must be supplied with flow control valve to prevent gravity circulation Reduced pressure back flow preventer must be used under provisions required by the Environmental Protection Agency EPA Bypass piping is an option which gives ability to adjust supply boiler water temperature to fit
12. be removed from boiler for cleaning without disconnecting tubing See Figures 16 amp 17 below e Optional flexible oil line is available Figure 17 Typical Installation Two Pipe Oil System APPROVED FITTINGS BAROMETRIC DRAFT CONTROL SHUT OFF VALVE OIL FILTER SUCTION LINE EB VA SSE LL Bri Valli OIL BURNER OIL LINE MUST BE BURIED OR OTHERWISE PROTECTED FROM OTHERWISE PROTECTED FROM DAMAGE MINIMUM 3 8 IPS OR 3 8 O D COPPER TUBING OIL FILTER DAMAGE MINIMUM 1 2 IPS OR 1 2 O D COPPER TUBING 17 ELECTRICAL WIRING Sequence Of Operations On call for heat thermostat will actuate completing circuit to limit In turn circulator and ignition systems are activated and ignition will begin In event boiler water temperature exceeds high limit setting on boiler mounted limit power will be interrupted between limit and ignition system Power will remain off until boiler water temperature drops below high limit setting Circulator will continue to operate under this condition until thermostat is satisfied Electrical shock hazard Turn OFF electrical power supply at service panel before making electrical connections Failure to do so could result in death or serious injury Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction Refer to e USA National Electrical Code ANSI NFPA 70 Install f
13. ermanent openings one starting 12 inches from the top and one 12 inches from the bottom of the enclosed space Each opening shall have a minimum free area of 1 square inch per one thousand 1 000 Btu per hour of the total input rating of all appliances in the enclosed space but must not be less than one hundred 100 square inches These openings must freely communicate with the interior areas having adequate infiltration from the outside See Figure 1 When the boiler is installed in a confined space and all air is provided from the outdoors the confined Space Shall be provided with two permanent openings one commencing within 12 inches from the top and one commencing 12 inches from the bottom of the enclosure The openings shall communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors One of the following methods must be used to provide adequate air for ventilation and combustion A When directly communicating with the outdoors each opening shall have a minimum free area of 1 square inch per 4 000 Btu per hour of total input rating of all equipment in the enclosure See Figure 2 Figure 1 CHIMNEY OR LTYPE VENT PIPE Yi Wr SENSN NS B When communicating with the outdoors by means of vertical ducts each opening shall have a minimum free area 1 square inch per 4 000 Btu per hour of total input rating of all appliances in the enclosed space See Figure
14. etain for future reference Boiler installation shall be completed by qualified agency Become familiar with symbols identifying potential All boiler and venting installations shall be done hazards by qualified agency and in accordance with appropriate Manufacturer s Installation Operation A and Maintenance Manual Installing or venting boiler This is the safety alert symbol Symbol alerts you to or any other appliance with improper methods or potential personal injury hazards Obey all safety messages materials could result in serious injury or death due following this symbol to avoid possible injury or death to fire or to asphyxiation from poisonous gases such as carbon monoxide which is odorless and invisible 44 DANGER Indicates a hazardous situation which if not a Modification substitution or elimination of factory avoided WILL result in death or serious injury equipped supplied or specified components could result in death or serious injury eic f PAR situation which if not avoided Keep boiler area clear and free from combustible could result in death or serious Injury materials gasoline and other flammable vapors and liquids DO NOT obstruct air openings to boiler room Indicates a hazardous situation which if not avoided To the owner Installation and service of this boiler must could result in minor or moderate injury be performed by qualified installer To the installer Leave all instructions
15. largest boiler part to enter or to permit replacement of another appliance such as water heater Fire hazard Do not install boiler on combustible flooring or carpeting Failure to follow these instructions could result in death or serious injury Boiler must not be installed on carpeting or vinyl flooring Minimum clearances to combustible construction are jo d 24 IN gadgets 24 IN FLUE CONNECTOR 2122 000000001xtadslvr nas 9 IN REA Lomas Es Edu UN MR UD 6 IN SIDES usto UI ICT VUPSUINISIT 6 IN NOTICE Clearance for access should exceed fire protection clearance REMOVE CRATE and plastic protective wrapper inspect for damage Move boiler to permanent position by sliding or walking VENTILATION amp COMBUSTION AIR Asphyxiation fire hazard Do not obstruct air openings to combustion area Follow instructions 1 below to maintain adequate combustion air COMBUSTION AIR REQUIREMENTS MINIMUM OPENING IN SQUARE INCHES UNCONFINED AREA CONFINED AREA OUTSIDE INSIDE OUTSIDE COMBUSTION AIR COMBUSTION AIR COMBUSTION AIR 1 IN2 5000Btu HR PARAGRAPH 4 1 IN 1000 Btu HR MIN 100IN2 Figure 1 IN 4000 Btu HR Figures 2 amp 3 1 IN7 2000 Btu HR Figure 4 Unconfined area A space whose volume is not less than 50 cubic feet per 1000 Btu per hour of all appliances installed in that space cubic feet of space height x width x length Confined area A space whose volume is less than 50 c
16. llowing tables page 25 are provided as guideline for initial start up Final adjustments MUST be made using combustion instruments as previously mentioned Check Safety Control Circuit for satisfactory performance after burner adjustments have been made 1 High limit control remove cover and note temperature setting See Figure 26 With burner operating decrease setting to minimum point When boiler water temperature exceeds this set point high limit switch will open shutting off power to oil burner Return setting to desired high limit point Burner should restart Refer to instructions included with limit 2 Primary control and flame sensor check following A Flame failure simulate by shutting off oil supply with hand valve while burner is on After flame extinguishes control goes through recycle period and attempts another ignition then locks out To restart open oil supply valve and reset safety switch Refer to instructions included with burner B Ignition failure with burner off close oil supply valve and run through start up procedure The safety switch should lock out as in flame failure C Power failure Turn off main power supply switch while burner is operating When burner stops restore power and burner should start If operation is not as described as above check wiring and controls 23 OPERATING INSTRUCTIONS Preventive Maintenance of oil fired boiler reduces operating costs Boiler and
17. n of building within 10 feet See Figure 15 It should produce negative draft of 06 to 08 inches of water column W C as measured with draft gauge between boiler and barometric draft control while maintaining 02 inch W C negative draft in combustion chamber See chart Chimney or Vent Sizes for recommended chimney or vent sizes Inadequate draft will cause improper combustion resulting in dirty flue ways and high fuel bills CONNECT FLUE PIPE same size as boiler outlet to chimney sloping upward continuously toward chimney approximately 1 4 per foot Bolt or screw joints together to avoid sag If oil fired water heater is vented into same flue as boiler provide separate hole into chimney whenever possible When not possible use Y connection in flue pipe using separate draft regulator for each unit When chimney will not provide adequate draft to handle input from water heater and boiler simultaneously wire units so that only one will operate at a time favoring water heater 16 OIL TANK AND PIPING Install burner per instructions provided with burner in a box kit Install oil tank and piping in accordance with the National Board of Fire Underwriters and local regulations Oil storage tank vent fill pipe and caps should be as prescribed by local codes In no case should vent pipe be smaller than 1 I P S Fill pipe should not be less than 2 I P S Suction line from tank to burner
18. r Swing open burner and door to the left Brush using flue brush soot and scale into combustion Space where it can be removed through swing door opening It is recommended to replace nozzle at start of each heating season Lubricate burner motor and circulator motor if required with few drops of good grade light motor oil Do not over oil Have service agent service burner check controls and check electrodes for carbon or cracks in insulators Burners should be adjusted to produce conditions shown in Start up and Adjustment of Oil Burner procedure covered earlier in this section Use caution when vacuuming in the chamber area Damage to chamber could result OPERATING INSTRUCTIONS TABLE 1 BECKETT AFG SETTINGS PUMP BOILER HEAD HEAD STATIC MODEL TYPE SETTING PLATE NOZZEE E SFH 3085W Li 3 075 609B 140 SFH 3100W T Li 3 0 85 60 B _ 140 SFH 100W T vi 0 2 0 85 60 B 140 SFH 4125W T Vi 0 2 1 10 60 B _ 140 140 SFH 5160W T F12 2 1 35 70B _ 140 SFH 5185W T F12 2 1 50 709B _ 150 SFH 6175W T F12 150 709 140 SFH 6210W T F16 175 45 1 1 1 1 1 12 12 12 16 1 75 709B 1 TABLE 2 RIELLO 40F5 40F10 SETTINGS RIELLO BURNER PUMP BURNER INSERTION PRESSURE E GATE MODEL INCHES SETTING 1 35x609W TABLE 3 CARLIN EZ 1 2 SETTINGS BAND BOILER BURNER FIRING
19. re e CR ee HOT WATER m OUTLET PRESSURE m REDUCING eS VALVE d FEED WATER A COE Z E THERMAL TRAP RELIEF VALVE WIRING FOR DRAIN VALVE fo THERMOSTAT PUMP CONTROL 12 SYSTEM PIPING Burn or Scald Hazard Discharge line shall be installed to relief valve outlet connection to avoid burns scalding or water damage due to discharge of steam and or hot water during operation Discharge line shall e Connect to safety valve outlet Piped down to safe point of disposal Check local codes for maximum distance from floor or allowable safe point of discharge e Pipe size be of equal to or greater than of safety valve outlet over entire length of discharge line e Have no intervening shutoff valve between safety valve and discharge to atmosphere Do not plug or place any obstruction in discharge line e Terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing e Allow complete drainage of valve and discharge line e Install safety valve with spindle in vertical position e Do not install shutoff valve between boiler and safety valve e Support safety valve discharge piping e Be short and straight as possible e Terminate with plain end not threaded e Constructed of material suitable for exposure to temperatures of 375 F 191 C or greater Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation requirements
20. should be one continuous piece of tubing to prevent air entering line Suction line must be 3 O D copper tubing for runs of 50 feet or less and 1 2 O D for longer runs Oil return line same size as suction line must be used on any installation where bottom of tank is below fuel unit of burner Oil lines should be buried or otherwise protected from mechanical injury Flare fittings on all oil lines are recommended Compression fittings on suction line often allow air to be drawn into fuel pump making it difficult to maintain oil pressure at nozzle Figure 16 Typical Installation Single Pipe Oil System BAROMETRIC DRAFT CONTROL REFER TO NATIONAL BOARD OF FIRE UNDERWRITERS p 3 MINIMUM mu BOILER OIL GAUGE OIL BURNER SHUT OFF VALVE OIL LINE MUST BE BURIED OR e Do not run overhead fuel lines from tank to oil burner e Fuel pump connections and by pass should be made according to instructions attached to fuel pump If tank is more than 20 from boiler a two stage fuel unit should be installed in place of single stage pump supplied as standard equipment with burner Make certain rotation and speed are same and pump is suitable for burner horsepower rating Oil line filter and shut off valve should be installed in suction line Shut off valves should be installed in both suction and return lines at burner for convenience in servicing burner e Allow extra tubing at burner so burner may
21. system or condition of installation Although this method of piping is not typically required for baseboard heating systems GATE VALVE CIRCULATOR Ho n B an NCMO 3d P R l SUPPLY PIPING pot ea M e TO HEATING Li AND COOLING E PRESSURE l ELEMENT REDUCING m SIT EXPANSION FEED kaa TANK WATER l DI D l RETURN PIPING j FROM HEATING p CHECK Ls AND COOLING VALVE ELEMENT te _ zJddo 71 xV YI CONNECTING SUPPLY AND RETURN PIPING A This method is used to protect boilers from condensate forming due to low temperature return water Generally noticed in large converted gravity systems or other large water volume systems See Figure 6 B These methods are used to protect systems using radiant panels and material they are encased in from high temperature supply water from boiler and protect boiler from condensation See Figures 7 and 8 following page C This method is used to protect boilers from condensate forming as well as protecting heating system from high water temperature See Figure 8 following page Note When using bypass piping adjust valves A and B until desired system temperature is obtained 7 Bypass loop piping must be same size piping for supply and return Figure 6 Bypass Piping SUPPLY a SYSTEM Fimm TEMPERATURE V GAUGE Tt FLOW VALVE REDUCED PRESSURE I BACKFLOW PREVENTER E nan GATE VALVE ZONE Lev VALVE a CIR pS ff K
22. tion Operation and Maintenance Manual Due to varying water conditions adjustable flow restricter must be installed in cold water inlet of this coil 14 CONNECTING SUPPLY AND RETURN PIPING OPTIONS UTILIZING 3 4 TAPPING Figure 13 Optional Location For Air Vent SUPPLY 22eA A A P 53 lt wmwm 2 SUPPLY H AIR VENT ATTACHED TAPPING TO 3 4 TAPPING RETURN Figure 14 Optional Location For Expansion Tank Non Diaphragm Type EXPANSION TANK VY AN SUPPLY l 2 SUPPLY K TAPPING F 3 4 TAPPING RETURN VENTING SYSTEM INSPECTION amp INSTALLATION INSPECT CHIMNEY to verify it is constructed according to latest revision of the NFPA 211 Local codes may differ from this code and should be checked Where there is a conflict local code will prevail Figure 15 MORE THAN 10 3 1 M e Boiler must be installed into chimney which has masonry or metallic chimney liner ene HEIGHT ABOVE ANY ROOF SURFACE WITHIN 10 3 1 M HORIZONTALLY Unlined chimney will have leaks that will cause poor chimney performance NO DRAFT and could result in positive pressure in combustion chamber Horizontal portions of venting system should not exceed 10 feet in length Horizontal lengths over 10 feet will have negative effect on chimney performance CHIMNEY 3 92 M MIN GAS VENT OR TYPE L VENT 2 61 M MIN Chimney should extend at least 2 feet above any portio
23. ubic feet per 1000 Btu per hour of all appliances installed in that space cubic feet of space height x width x length Ventilation of boiler room must be adequate enough to provide sufficient air to properly support combustion When boiler is located in an unconfined space in a building of conventional construction frame masonry or metal infiltration normally is adequate to provide air for combustion and ventilation However in any building which has been altered to conserve energy or to minimize infiltration the boiler area should be considered as a CONFINED SPACE Provide combustion air and ventilation air in accordance with the section Air for Combustion and Ventilation of NFPA 31 Standard for the Installation of Oil Burning Equipment When a boiler is installed in an unconfined space in a building of unusually tight construction air for combustion and room ventilation must be obtained from outdoors or from spaces freely communicating with the outdoors A permanent opening or openings having a total free area of not less than 1 square inch per 5 000 Btu per hour of total input rating of all appliances shall be provided Ducts may be used to convey make up air from the outdoors and shall have the same cross sectional area of the openings to which they are connected VENTILATION amp COMBUSTION AIR 4 When air for combustion and room ventilation is from inside buildings confined space shall be provided with two p
24. used disconnect switch between boiler and meter at convenient location Thermostat Installation 1 Thermostat should be installed on inside wall about four feet above the floor 2 NEVER install thermostat on outside wall 3 Do not install thermostat where it will be affected by e Drafts e Hot or cold pipes e Sun light e Lighting fixtures e Television sets e Fireplace or chimney 4 Check thermostat operation by raising and lowering thermostat as required to start and stop burner 5 Instructions for final adjustment of thermostat are packaged with thermostat adjusting heating anticipator calibration ect 18 ELECTRICAL WIRING Figure 18 Wiring Diagram Beckett AFG without Tankless Heater LIMIT SENSOR BURNER CONTROL DECRETI 7303 PRIMARY CUNTRUL THERMOSTAT 24 VOLT BY INSTALLER IGNITER BLU WHT L2 WHT MOTOR ORG L2 WHT BLK ZILA Ip LIMIT BLK 120V 60 HZ L2 WHT SUPPLY BY INSTALLER VALVE VI L2 WHT CAD CELL YEL RED CIRCULATOR CAD CELL YEL Figure 19 Wiring Diagram Beckett AFG wth Tankless Heater 120V 60 HZ SUPPLY BY INSTALLER BURNER CONTROL BELKETT 72305 THERMOSTAT PRIMARY CONTROL 24 VOLT BY INSTALLER IGNITER BLU WHT L2 WHT MOTOR ORG L2 WHT WHT LIMIT BLK L2 WHT BLK E N S VALVE VI oO L2 WHT BLK C GRN CAD CELL YEL RED CAD CELL YEL WHT CIRCULATOR 19 ELECTRICAL WI
25. vent pipe should be inspected for accumulation of soot or scale deposits periodically but at least once every year before start of each heating season When soot is present on section walls and flueways improper combustion will result causing additional sooting and scaling until flueways are completely closed To remove soot and scale from flueways remove top jacket panel top clean out plate open burner swing door See Figure 26 Periodic Inspection and tightening of tankless heater cover plate bolts will reduce risk of leaks See Replacement Parts Heat Exchanger section Instructions For Opening Burner Swing Door 1 Turn off power to boiler 2 Allow boiler to cool down 3 Disconnect power cable at factory supplied burner electrical disconnect See Figure 26 Loosen screws on the sides of lower front jacket panel See Figure 24 Pull bottom part of lower front panel forward Lift lower front panel up and off boiler See Figure 26 Burn scald hazard Do not attempt to start burner when excess oil has accumulated when unit is full of vapor or when combustion chamber is very hot NOTICE Use only number 2 fuel oil Do not use gasoline crankcase drainings or any oil containing gasoline 24 7 8 9 10 11 Close oil valve See Figures 16 amp 17 Disconnect oil line from burner Do not try to swing door with oil line attached Remove nut from swing door stud on right hand side of doo
26. with boiler for NIOeRBLG future reference Installation in Commonwealth of Massachusetts must be Used to address practices not rel rsonal i injury P ated to REA performed by Licensed Plumber or Licensed Gas Fitter DIMENSIONS DIMENSIONAL DATA 211 2 SUPPLY TAPPING FRONT OF BOILER CASING SECTION TO CENTER LINE OF JACKET FLUE OUTLET OUTLET 177 11 1 4 6 12 6 25 Ye 6 294 15154 BOILER RATINGS amp CAPACITIES LID Att CERTIFIED BOILER RATINGS www ahridirectory org eJ OIL DORNER pp eye NET x PREIS BOILER MODEL INPUT CAPACITY RATINGS A F U E NUMBER WAER Mbh 1 000 Btu per hour Btu British Thermal Unit 1 Oil burner input based on 140 000 Btu per gallon Net AHRI water ratings shown are based on a piping and pickup allowance of 1 15 Consult manufacturer before selecting a boiler for installation having unusual piping and pickup requirements such as intermittent system operation extensive piping systems etc 3 Heating Capacity and AFUE based on 13 0 CO2 with 0 02 W C draft over fire and 1 smoke or less Tested in accordance with U S Department of Energy test procedures T Tankless STANDARD EQUIPMENT Crated Boiler Flush Jacket Oil Burner Target Wall Liner Circulator 11 4 Safety Relief Valve Temperature Pressure Gauge Drain Valve Wiring Harness Burner Electrical Disconnect Plastic Cover Supply Tapping 2 Return Tapping 1 1 2

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